Mozal Aluminium, a major aluminium smelting operation producing ~575,000 tonnes per year, operates continuously – 24 hours a day, 7 days a week. With internal vehicle movements transporting molten metal and other intermediate products across its site, the company faces elevated risk at every interface between people and mobile equipment. Mozal Aluminium deployed Guardian to address this risk and enhance safety in its operations.

Within Mozal’s integrated risk-management framework (shared with South32), every incident – whether a near miss or material event – is logged, investigated, and analysed for root causes and contributing factors. Over time, recurring themes emerged: driver fatigue and distraction were flagged repeatedly as underlying elements in vehicle-related incidents.

To tackle this, Mozal first implemented Guardian in 2019, via its service provider SRMC that transported aluminium product to port, where the exposure to public roads and pedestrian interactions was high. Encouraged by early results, Mozal expanded use in 2023, requiring its employee bus transport contractors to adopt the same system. In 2024, Mozal took ownership of the initiative and deployed Guardian internally across more than 50 vehicles.

“Mozal’s assessment of Guardian was grounded in real-world outcomes. Early deployments through SRMC generated meaningful data highlighting reductions in distracted and fatigued driving behaviour, clear trends of improvement, and increased operational confidence. This evidence supported our broader rollout across Mozal’s internal operations.” – Anna May Fauconnier-Williams, VPO, Mozal.

Since full implementation, Mozal is seeing positive changes in safety culture and operational performance. Fatigue and distraction-related incidents have shown measurable improvements, with microsleep events reduced by an impressive 93 percent and a clear decline in mobile phone use while driving. Operators are now more self-aware, responding proactively to real-time alerts by taking breaks or refocusing as needed, which has strengthened the overall safety culture.

These changes have contributed to stronger safety performance metrics and tangible reductions in incidents, while also setting Mozal apart in the industry as a proactive leader in employee protection. Beyond operational outcomes, the company has also invested in building internal capability by upskilling its technicians as certified Guardian installation and maintenance specialists, ensuring long-term, in-house support for the technology.

Collectively, these efforts not only demonstrate Mozal’s and South32’s commitment to eliminating vehicle-related incidents and safeguarding employees but also highlight their competitive advantage as a mature safety leader with greater control over critical risks.

Installing Guardian has reinforced Mozal Aluminium’s commitment to the belief that strong controls and technology can prevent fatal incidents, particularly in high-risk vehicle operations. Learn more in this case study.

“Controls save lives.” – Anna May Fauconnier-Williams, VPO, Mozal.

In environments where human lives and heavy machinery intersect, Mozal’s level of commitment builds trust and sets a new benchmark for operational excellence.